2/2-way angle-seat control valve 2/2-Wege-Schrägsitzregelventil Vanne de réglage à siège incliné 2/2 voies Operating Instructions Bedienungsanleitung Manuel d utilisation
We reserve the right to make technical changes without notice. Technische Änderungen vorbehalten. Sous réserve de modifications techniques. Bürkert Werke GmbH & Co. KG, 2008-2018 Operating Instructions 1802/09_EU-ML_00805626 / Original DE
Contents 1 OPERATING INSTRUCTIONS... 4 1.1 Symbols... 4 1.2 Definition of term / abbreviation... 4 2 INTENDED USE... 5 3 BASIC SAFETY INSTRUCTIONS... 5 4 GENERAL INFORMATION... 7 4.1 Contact address... 7 4.2 Warranty... 7 4.3 Information on the internet... 7 5 PRODUCT DESCRIPTION... 7 5.1 General description... 7 5.2 Versions... 7 5.3 Properties... 8 5.4 Designated application area... 9 6 STRUCTURE AND FUNCTION... 9 6.1 Structure... 9 6.2 Function... 10 8 INSTALLATION... 22 8.1 Safety instructions... 22 8.2 Before installation... 23 8.3 Installation... 24 8.4 Pneumatic connection... 28 8.5 Start-up... 29 8.6 Removal... 29 9 ELECTRICAL CONTROL UNIT... 29 10 MAINTENANCE, CLEANING... 30 10.1 Safety instructions... 30 10.2 Maintenance work... 30 10.3 Replacing the wearing parts... 31 11 MALFUNCTIONS... 40 12 REPLACEMENT PARTS... 41 12.1 Replacement part sets... 41 12.2 Installation tools... 43 13 PACKAGING, TRANSPORT, STORAGE... 43 7 TECHNICAL DATA... 12 7.1 Conformity... 12 7.2 Standards... 12 7.3 Type label... 12 7.4 Operating conditions... 12 7.5 Flow values and characteristics... 17 7.6 General technical data... 21 3
Operating instructions 1 OPERATING INSTRUCTIONS The operating instructions describe the entire life cycle of the device. Keep these instructions in a location which is easily accessible to every user and make these instructions available to every new owner of the device. The operating instructions contain important safety information! Failure to observe these instructions may result in hazardous situations. The operating instructions must be read and understood. 1.1 Symbols DANGER! Warns of an immediate danger! Failure to observe the warning may result in a fatal or serious injury. WARNING! Warns of a potentially dangerous situation! Failure to observe the warning may result in serious injuries or death. CAUTION! Warns of a possible danger! Failure to observe this warning may result in a moderately severe or minor injury. NOTE! Warns of damage to property! Failure to observe the warning may result in damage to the device or the equipment. Indicates important additional information, tips and recommendations. Refers to information in these operating instructions or in other documentation. designates instructions for risk prevention. Designates a procedure which you must carry out. 1.2 Definition of term / abbreviation The term device used in these instructions always stands for the angle-seat control valve Type 2300. The abbreviation Ex used in these instructions always stands for explosion-protected. 4
Intended use 2 INTENDED USE Non-intended use of the angle-seat control valve Type 2300 may be a hazard to people, nearby equipment and the environment. The device is designed for the controlled flow of liquid and gaseous media. Operation is possible only in combination with a suitable control unit. In the potentially explosion-risk area the globe valve type 2300 may be used only according to the specification on the separate Ex type label. For use observe the additional information enclosed with the device together with safety instructions for the explosion-risk area. Devices without a separate Ex type label may not be used in a potentially explosive area. The admissible data, the operating conditions and conditions of use specified in the contract documents, operating instructions and on the type label are to be observed during use. These are described in the chapter entitled 7 Technical data. Protect device from damaging environmental influences (e.g. radiation, humidity, steam, etc.). If anything is unclear, consult the relevant sales office. The device may be used only in conjunction with third-party devices and components recommended and authorized by Bürkert. Correct transportation, correct storage and installation and careful use and maintenance are essential for reliable and faultless operation. Use the device only as intended. 3 BASIC SAFETY INSTRUCTIONS These safety instructions do not make allowance for any contingencies and events which may arise during the installation. operation and maintenance of the devices. local safety regulations; the operator is responsible for observing these regulations, also with reference to the installation personnel. DANGER! Risk of injury from high pressure in the equipment or device! Before working on equipment or device, switch off the pressure and deaerate or drain lines. Risk of injury from electric shock (when electrical component installed). Before reaching into the device, switch off the power supply and secure to prevent reactivation! Observe applicable accident prevention and safety regulations for electrical equipment! 5
Basic safety instructions WARNING! Risk of injury when opening the actuator! The actuator contains a tensioned spring. If the actuator is opened, there is a risk of injury from the spring jumping out! The actuator must not be opened. Risk of injury from moving parts in the device! Do not reach into openings. Danger due to loud noises. Depending on the operating conditions, the device may generate loud noises. More detailed information on the likelihood of loud noises is available from the relevant sales office. Wear hearing protection when in the vicinity of the device. CAUTION! Risk of burns! The surface of the device may become hot during long-term operation. Do not touch the device with bare hands. Leaking medium when the packing gland is worn. Regularly check relief bore for leaking medium. If the media is hazardous, protect the area surrounding the discharge point against dangers. General hazardous situations. To prevent injury, ensure that: That the system cannot be activated unintentionally. Installation and repair work may be carried out by authorized technicians only and with the appropriate tools. After an interruption in the power supply or pneumatic supply, ensure that the process is restarted in a defined or controlled manner. The device may be operated only when in perfect condition and in consideration of the operating instructions. Observe the safety regulations specific to the plant for application planning and operation of the device. The plant operator is responsible for the safe operation and handling of the plant. The general rules of technology apply to application planning and operation of the device. To prevent damage to property of the device, ensure: Supply the media connections only with those media which are specified as flow media in the chapter entitled 7 Technical data. Do not put any loads on the valve (e.g. by placing objects on it or standing on it). Do not make any external modifications to the valves. Do not paint the body parts or screws. Do not transport, install or remove heavy devices without the aid of a second person and using suitable auxiliary equipment. The exhaust air may be contaminated with lubricants in the actuator. 6
General information 4 GENERAL INFORMATION 4.1 Contact address Germany Bürkert Fluid Control System Sales Centre Christian-Bürkert-Str. 13-17 D-74653 Ingelfingen Tel. + 49 (0) 7940-10 91 111 Fax + 49 (0) 7940-10 91 448 E-mail: info@burkert.com International Contact addresses are found on the final pages of the printed operating manual. You can also find information on the Internet under: www.burkert.com 4.2 Warranty The warranty is only valid if the device is used as authorized in accordance with the specified application conditions. 4.3 Information on the internet The operating instructions and data sheets for Type 2300 can be found on the Internet at: www.burkert.com 5 PRODUCT DESCRIPTION 5.1 General description The 2/2-way angle-seat control valve Type 2300 is suitable for liquid and gaseous media. It uses neutral gases or air (control media) to control the flow of water, alcohol, oil, fuel, hydraulic fluid, saline solution, lye, organic solvent and steam (flow media). The operation of the angle-seat control valve Type 2300 is possible only in combination with an control unit. Possible control units are: Positioner Type 8692, 8694 and 8696 Process controller Type 8693 5.2 Versions There are 2 versions of the angle-seat control valve Type 2300. Standard version without separate Ex type label. The standard version must not be used in the potentially explosive area. Ex version with separate Ex type label. The Ex version may be used in the potentially explosive area. In doing so, observe the specifications on the separate Ex type label and the additional information enclosed with the device together with safety instructions for the Ex area. 7
Product description 5.3 Properties Direct installation of the positioners Type 8692 / 8694 / 8696 or the process controller Type 8693. High tightness by self-adjusting packing glands (spindle sealing element). Closes tightly when using the PTFE control cone. High flow values by the streamlined valve body made of stainless steel. Simple and fast replacement of the control cone. Actuator can be rotated steplessly through 360. Maintenance-free under normal conditions. 5.3.1 Technical features Characteristic: modified equal-percentage flow characteristic. Theoretical setting ratio (Kv S / Kv 0 ) 50:1; alternatively, other setting ratios can be realized. Kv R value, i.e. the smallest Kv value at which the angularity tolerance according to DIN IEC 534-2-4 is still maintained: DN20 Kv R at 10 % of the stroke > DN20 Kv R at 5 % of the stroke 5.3.2 Options Control unit: Depending on the requirement, control units in various designs are available. Positioner Type 8692, 8694 and 8696 Process controller Type 8693 Vacuum Food conformity FDA DVGW ATEX 5.3.3 Device versions Pilot pressure Designs with lower pilot pressure (reduced spring force) are available on request. Contact your Bürkert sales office or our Sales Centre. E-mail: info@de.buerkert.com Actuator sizes Depending on the orifice, the angle-seat control valve is available for the following actuator sizes: Orifice DN Available actuator size ø [mm] 15 50 70-20 50 70-25 50 70 90 32 70 90 40 90 130-50 - 90 130 65-130 Tab. 1: Actuator sizes 8
Structure and function 5.4 Designated application area Observe the maximum pressure range according to the type label! Neutral gases and liquids up to 16 bar. Steam up to 11 bar absolute / 185 C for seat seal steel / steel. Steam up to 2.7 bar absolute / 130 C for seat seal PTFE / steel. Aggressive media. 5.4.1 Application areas e.g. Plant construction Food processing Chemical engineering Sterilizer construction, temperature control Gas dosing Conveyor systems for various bulk material (also sensitive foodstuff) 6 STRUCTURE AND FUNCTION The operation of the angle-seat control valve Type 2300 is possible only in combination with a control unit. Possible control units are: Positioner Type 8692, 8694 and 8696 Process controller Type 8693 6.1 Structure The angle-seat control valve consists of a pneumatically operated piston actuator, a control cone and a 2/2-way angleseat body. Via a dowel pin, the control cone is modularly coupled to the actuator spindle for quick changeovers. For the body, almost any line connections are possible. A threaded port and a welded end are offered as a standard version. The valve seats are incorporated directly. The flow inlet is always under seat. The description of the control function (CF) can be found in chapter entitled 6.2.1 Control functions (CF). 9
Structure and function 2 1 Exhaust air port for CFA, CFB Pilot air port for CFI Pilot air port for CFA, CFB, CFI Actuator cover Actuator body Interface actuator/body with wrench flat Angle-seat body 6.2 Function The seat of the valve is always closed against the medium flow. Spring force (CFA) or pneumatic pilot pressure (CFB and CFI) generates the closing force on the control cone. The force is transferred via a spindle which is connected to the actuator piston. 6.2.1 Control functions (CF) WARNING! For control function I Danger if pilot pressure fails! For control function I control and resetting occur pneumatically. If the pressure fails, no defined position is reached. To ensure a controlled restart, first pressurize the device with pilot pressure, then switch on the medium. Control function A (CFA) Normally closed by spring action. Numbers for indicating the direction of flow Port connection Fig. 1: Angle-seat control valve Type 2300, structure and description 10
Structure and function Control function B (CFB) Normally open by spring action. Control function I (CFI) Actuating function via reciprocal pressurization. 6.2.2 Flow direction below the seat Depending on the version, the valve is closed against the medium flow with spring force (control function A, CFA) or with pilot pressure (control function B or I, CFB or CFI). As the medium pressure is under the control cone, this pressure contributes to the opening of the valve. WARNING! Medium may be discharged if minimum pilot pressure is too low or medium pressure too high! If the minimum pilot pressure is too low for CFB and CFI or the permitted medium pressure is exceeded, leaks may occur. Observe minimum pilot pressure. Do not exceed medium pressure. See chapter entitled 7.4.3 Pressure ranges. Rest position CFA Rest position CFB/CFI Fig. 2: Flow direction below the seat (Rest open/closed, closing against medium) 11
Technical data 7 TECHNICAL DATA 7.1 Conformity Type 2300 conforms with the EU Directives according to the EU Declaration of Conformity. 7.2 Standards The applied standards, which verify conformity with the EU Directives, can be found on the EU-Type Examination Certificate and / or the EU Declaration of Conformity. According to Pressure Equipment Directive the following operating conditions must be observed: Line connection orifice DN65 Maximum pressure for compressible fluids of Group 1 (hazardous gases and vapors according to Art. 3 No. 1.3 Letter a first dash) 15 bar 7.3 Type label Orifice of the body / actuator size Control function (CF) Type 00285864 Identification number of the device Sealing material 1) Body material 1) Permitted medium temperature Permitted medium pressure Permitted pilot pressure 2300 A 25M PTFE VA Tmed -10 C - +130 C Pilot 5,5-7bar Pmed 12bar Flow 1 2 G1 Kvs16 Flow direction CE identification CE W1XMS Date of manufacture Main dimensions of line connection Flow capacity in standard production conditions 1) For description of versions see 7.6 General technical data 7.4 Operating conditions Observe permitted ranges on the type label of the device! 12
Technical data 7.4.1 Temperature ranges Actuator size [mm] ø 50 ø 70 ø 90 ø 130 Tab. 2: Actuator material Medium Seat seal steel / steel Seat seal PTFE / steel Environ-ment 2) -10...+60 C3) PPS -10...+185 C -10...+130 C -10...+100 C 4) Temperature ranges 2) If a pilot valve/control unit is used, the max. ambient temperature is +55 C. The angle-seat control valve is suitable for steam sterilization. 7.4.2 Control medium In conjunction with pneumatic control units (positioner or process controllers), pilot air according to DIN ISO 8573-1 must be used: Class 3 (for water content) Class 5 (for dust and oil content). The specification is described in detail in the operating instructions of the respective positioner / process controller in the chapter entitled Technical data. 7.4.3 Pressure ranges Pilot pressure range 5) on controlled operation Actuator Orifice DN Pilot pressure range 5) [bar] size [mm] CFA CFB ø 50 mm 15 25 3.4 5.5 3.3 5.1 ø 70 mm 15 32 2.6 5.5 2.6 5.2 ø 90 mm 25 50 3.3 5.5 1.8 2.5 ø 130 mm 40 50 3.3 5.6 1.9 2.7 65 4.6 5.6 1.9 2.7 Tab. 3: Pilot pressure range on controlled operation 3) Pilot air ports with push-in connector 4) Pilot air ports with threaded bushing. 5) To ensure reliable operation with pneumatic control units (positioner or process controller), observe the permitted minimum and maximum pilot pressure! 13
Technical data Maximum pilot pressure for valves without pneumatic control unit Actuator size Actuator material max. permitted pilot pressure 6) ø 50 mm ø 70 mm 10 bar PPS ø 90 mm ø 130 mm 7 bar Tab. 4: Pilot pressure for valves without pneumatic control unit 6) Observe the maximum pressure range according to the type label! Operating pressure for control function A 7) Actuator size Orifice DN [mm] Required pilot pressure [bar] Max. sealed medium pressure [bar] 15 5.5 16 ø 50 mm 20 5.5 10 25 5.5 5 15 5.5 16 ø 70 mm 20 5.5 16 25 5.5 12 32 5.5 6 25 5.5 16 ø 90 mm 32 5.5 16 40 5.5 12 50 5.5 7 40 5.5 16 ø 130 mm 50 5.5 16 65 5.6 16 (15*) Tab. 5: Operating pressure for control function A * According to Pressure Equipment Directive for compressible fluids of Group 1 (hazardous gases and vapors according to Art. 3 No. 1.3 Letter a first dash) 7) The description of the control function (CF) can be found in chapter entitled 6.2.1 Control functions (CF). 14
Technical data Pilot pressure for control function B 8) Actuator size ø 50 mm ø 70 mm ø 90 mm ø 130 mm Tab. 6: Pilot pressure[bar] Max. permitted medium Orifice DN for medium pressure [mm] 0 bar max pressure [bar] 15 4.6 6.6 16 20 5.1 7.0 9 25 5.1 7.0 5 15 4.4 5.3 16 20 5.2 6.8 16 25 5.2 7.0 12 32 5.2 7.0 6 25 2.4 4.2 16 32 2.4 5.3 16 40 2.5 6.5 16 50 2.5 7.0 14 40 2.7 4.5 16 50 2.7 5.6 16 65 2.7 7.0 16 (15*) Pilot pressure for control function B * According to Pressure Equipment Directive for compressible fluids of Group 1 (hazardous gases and vapors according to Art. 3 No. 1.3 Letter a first dash) Required minimum pilot pressure depending on medium pressure for circuit function B ø 50 CFB Medium pressure [bar] Fig. 3: 16 14 12 10 8 6 4 2 0 DN20 DN25 0 1 2 3 4 5 6 7 8 9 10 Pilot pressure [bar] Pressure graph, actuator ø 50 mm, control function B DN15 Designs with lower pilot pressure (reduced spring force) are available on request. 8) The description of the control function (CF) can be found in chapter entitled 6.2.1 Control functions (CF). 15
Technical data ø 70 CFB 16 Medium pressure [bar] DN15 DN20 14 12 DN25 10 8 6 DN32 4 2 0 0 1 2 3 4 5 6 7 8 9 10 Pilot pressure [bar] Fig. 4: Pressure graph, actuator ø 70 mm, control function B ø 130 CFB Medium pressure [bar] DN40 DN50 DN65 16 14 12 10 8 6 4 2 0 0 1 2 3 4 5 6 7 8 9 10 Pilot pressure [bar] Fig. 6: Pressure graph, actuator ø 130 mm, control function B ø 90 CFB Medium pressure [bar] DN25 DN32 DN40 16 DN50 14 12 10 8 6 4 2 0 0 1 2 3 4 5 6 7 8 9 10 Pilot pressure [bar] Fig. 5: Pressure graph, actuator ø 90 mm, control function B 16
Technical data 7.5 Flow values and characteristics Flow values for DN15 Stroke [%] Kv value [m 3 /h] Stroke [%] 5 0.16 60 3.5 10 0.17 70 4.0 20 0.22 80 4.5 30 0.4 90 4.8 40 1.2 100 5.0 50 2.7 Tab. 7: Flow values for DN15 Flow characteristics for DN15 Kv [m 3 /h] Fig. 7: Kv value [m 3 /h] 5,0 4,5 4,0 3,5 3,0 2,5 2,0 1,5 1,0 0,5 0,0 0 20 40 60 80 100 Stroke [%] Flow characteristics for DN15 Flow values for DN20 Stroke [%] Kv value [m 3 /h] Stroke [%] 5 0.26 60 7.2 10 0.27 70 8.3 20 0.4 80 9.1 30 1.1 90 9.6 40 4.0 100 10.0 50 5.9 Tab. 8: Flow values for DN20 Flow characteristics for DN20 Kv [m 3 /h] Fig. 8: Kv value [m 3 /h] 10,0 9,0 8,0 7,0 6,0 5,0 4,0 3,0 2,0 1,0 0,0 0 20 40 60 80 100 Stroke [%] Flow characteristics for DN20 17
Technical data Flow values for DN25 Stroke [%] Kv value [m 3 /h] Stroke [%] 5 0.34 60 11.5 10 0.36 70 13.0 20 0.62 80 14.2 30 1.5 90 15.4 40 5.2 100 16.0 50 8.9 Tab. 9: Flow values for DN25 Flow characteristics for DN25 Kv [m 3 /h] 16 14 12 10 8 6 4 2 Fig. 9: Kv value [m 3 /h] 0 0 20 40 60 80 100 Stroke [%] Flow characteristics for DN25 Flow values for DN32 Stroke [%] Kv value [m 3 /h] Stroke [%] 5 0.43 60 13.8 10 0.52 70 16.4 20 0.82 80 19.2 30 1.4 90 21.3 40 4.0 100 23.0 50 9.3 Tab. 10: Flow values for DN32 Flow characteristics for DN32 Kv [m 3 /h] Kv value [m 3 /h] 24 22 20 18 16 14 12 10 8 6 4 2 0 0 20 40 60 80 100 Stroke [%] Fig. 10: Flow characteristics for DN32 18
Technical data Flow values for DN40 - Actuator size ø 90 Stroke [%] Kv value [m 3 /h] Stroke [%] 5 0.47 60 21.5 10 0.62 70 25.3 20 1.1 80 28.8 30 2.6 90 31.6 40 10.0 100 34.0 50 17.0 Tab. 11: Flow values for DN40 - Actuator size ø 90 Flow characteristics for DN40 - Actuator size ø 90 Kv [m 3 /h] 35 30 25 20 15 10 5 Kv value [m 3 /h] 0 0 20 40 60 80 100 Stroke [%] Fig. 11: Flow characteristics for DN40 - Actuator size ø 90 Flow values for DN40 - Actuator size ø 130 Stroke [%] Kv value [m 3 /h] Stroke [%] 5 0.48 60 24.3 10 0.66 70 28.3 20 1.4 80 31.7 30 5.1 90 34.5 40 14.0 100 36.0 50 20.0 Tab. 12: Flow values for DN40 - Actuator size ø 130 Flow characteristics for DN40 - Actuator size ø 130 Kv [m 3 /h] 40 35 30 25 20 15 10 5 Kv value [m 3 /h] 0 0 20 40 60 80 100 Stroke [%] Fig. 12: Flow characteristics for DN40 - Actuator size ø 130 19
Technical data Flow values for DN50 - Actuator size ø 90 Stroke [%] Kv value [m 3 /h] Stroke [%] 5 0.85 60 28.6 10 1.1 70 35.6 20 1.6 80 40.6 30 2.7 90 45.0 40 10.2 100 49.0 50 20.0 Tab. 13: Flow values for DN50 - Actuator size ø 90 Flow characteristics for DN50 - Actuator size ø 90 Kv [m 3 /h] Kv value [m 3 /h] 50 45 40 35 30 25 20 15 10 5 0 0 20 40 60 80 100 Stroke [%] Fig. 13: Flow characteristics for DN50 - Actuator size ø 90 Flow values for DN50 - Actuator size ø 130 Stroke [%] Kv value [m 3 /h] Stroke [%] 5 0.87 60 35.0 10 1.2 70 40.3 20 1.8 80 45.0 30 4.0 90 48.0 40 15.2 100 53.0 50 26.0 Tab. 14: Flow values for DN50 - Actuator size ø 130 Flow characteristics for DN50 - Actuator size ø 130 Kv [m 3 /h] Kv value [m 3 /h] 55 50 45 40 35 30 25 20 15 10 5 0 0 20 40 60 80 100 Stroke [%] Fig. 14: Flow characteristics for DN50 - Actuator size ø 130 20
Technical data Flow values for DN65 - Actuator size ø 130 Stroke [%] Kv value [m 3 /h] Stroke [%] Kv value [m 3 /h] 5 1.7 60 58.0 10 2.0 70 67.0 20 6.5 80 75.0 30 20.0 90 83.0 40 35.0 100 90.0 50 48.0 Tab. 15: Flow values for DN65 - Actuator size ø 130 Flow characteristics for DN65 - Actuator size ø 130 90 80 70 Kv [m 3 /h] 60 50 40 30 20 10 0 0 20 40 60 80 100 Stroke [%] 7.6 General technical data Control functions (CF) The valve seat is always closed against the medium flow Control function A Control function B Control function I Actuator sizes Materials Valve body Actuator Sealing elements Spindle sealing Control cone Normally closed by spring action Normally open by spring action Actuating function via reciprocal pressurization (not for actuator size ø 50 mm in combination with Type 8696) ø 50 mm ø 70 mm ø 90 mm ø 130 mm 316L PPS and stainless steel FKM and EPDM PTFE V rings with spring compensation (with silicone grease) Control cone with PTFE seal Steel / steel seal Fig. 15: Flow characteristics for DN65 - Actuator size ø 130 21
Installation Spindle 1.4401 / 1.4404 Spindle guide Connections Pilot air port Medium connection Media Control medium Flow media Installation position 1.4401 / 1.4404 / 316L prepared for direct connection Threaded port: G ½ G 2 ½ (NPT, RC on request) Welded connection: as per EN ISO 1127 (ISO 4200), DIN 11850 R2 Other connections on request neutral gases, air Water, Alcohol, Fuel, Hydraulic liquids, Saline solutions, Lyes, Organic solvents as required, preferably with actuator in upright position Protection class IP67 in accordance with IEC 529/EN 60529 8 INSTALLATION 8.1 Safety instructions DANGER! Danger high pressure in the equipment! Before loosening the lines and valves, turn off the pressure and vent the lines. WARNING! Risk of injury from improper installation! Installation may be carried out by authorised technicians only and with the appropriate tools! Risk of injury from unintentional activation of the system and an uncontrolled restart! Secure system from unintentional activation. Following assembly, ensure a controlled restart. For control function I Danger if pilot pressure fails! For control function I control and resetting occur pneumatically. If the pressure fails, no defined position is reached. To ensure a controlled restart, first pressurize the device with pilot pressure, then switch on the medium. Risk of injury from moving parts in the device! Do not reach into openings. 22
Installation CAUTION! Risk of injury due heavy devices! During transport or during assembly, a heavy device may fall and cause injury. Do not transport, install or remove heavy devices without the aid of a second person and using suitable auxiliary equipment. Use appropriate tools. 8.2 Before installation The angle-seat control valve can be installed in any installation position, preferably with the actuator in upright position. Before connecting the valve, ensure the pipelines are flush. Make certain the flow direction is correct (Flow direction always below seat). 8.2.1 Preparatory work Clean pipelines (Sealing material, swarf, etc.). Devices with welded body NOTE! For valves with installed control: When welding the valve body into the pipeline, the control must not be installed. Remove control from the actuator described below. Remove the control unit from the actuator (if present): Clamp the valve body in a holding device. Loosen the fastening screws (2x). Remove the control unit upwards. Fastening screw (2x) Fig. 16: Disassembly the control unit Remove the actuator from the valve body. Control unit Actuator Install collet (white grommet) in pilot air port 1. NOTE! Damage to the seat seal or the seat contour! When removing the actuator, ensure that the valve is in open position. Control function A pressurize the pilot air port 1 with compressed air (5 bar): valve opens. Using a suitable open-end wrench, place the wrench flat on the pipe. 23
Installation Unscrew the actuator from the valve body. Exhaust air port CFA, CFB Pilot air port CFI Pilot air port CFA, CFB, CFI Flats for openend wrench Valve body Fig. 17: Installation Other device versions 2 1 Install collet: Actuator Nipple Do not remove actuator unless this is a customer-specific requirement. Procedure see Devices with welded body. 8.3 Installation WARNING! Risk of injury from improper installation! Assembly with unsuitable tools or non-observance of the tightening torque is dangerous as the device may be damaged. For installation use an open-end wrench, never a pipe wrench. Observe the tightening torque (see Tab. 16: Tightening torques of valve body / nipples ). Dirt trap for devices with authorisation in accordance with DIN EN 161 In accordance with DIN EN 161 Automatic shut-off valves for gas burners and gas appliances a dirt trap must be connected upstream of the valve and prevent the insertion of a 1 mm plug gauge. If the authorisation also applies to stainless steel bodies, the same type of dirt trap must be attached in front of the angleseat control valve. 24
Installation 8.3.1 Installation of the valve body Welded bodies Weld valve body in pipeline system. Other body versions Connect body to pipeline. 8.3.2 Install actuator (welded body) Fig. 18: Seal Seal Check the seal and if required, replace it. WARNING! Danger if incorrect lubricants used! Unsuitable lubricant may contaminate the medium. In oxygen applications there is a risk of an explosion! In specific applications, e.g. oxygen or analysis applications, use appropriately authorized lubricants only. Grease nipple thread before re-installing the actuator (e.g. with Klüber paste UH1 96-402 from Klüber). NOTE! Damage to the seat seal or the seat contour! When installing the actuator, ensure that the valve is in open position. Control function A pressurize the pilot air port 1 with compressed air (5 bar): valve opens. Screw actuator into the valve body. Observe tightening torque (see Tab. 16 ). Pilot air port Fig. 19: Connections 2 1 Tightening torques of valve body / nipples DN Tightening torque [Nm] 15 45 ±3 20 50 ±3 25 60 ±3 32 40 65 ±3 50 70 ±3 65 100 ±3 Tab. 16: Tightening torques of valve body / nipples 25
Installation 8.3.3 Install control unit Before installation, check the position of the ports on the control unit and, if required, align the actuator. Description see chapter 8.3.4 Rotating the actuator. Remove collet from pilot air port 1. Check that the O-rings are correctly positioned in the pilot air ports. Align the puck holder and the control unit until 1. the puck holder can be inserted into the guide rail of the control unit and 2. the supports of the control unit can be inserted into the pilot air ports of the actuator (see also Fig. 21 ). NOTE! Damaged printed circuit board or malfunction! Ensure that the puck holder is situated flat on the guide rail. Guide rail Push the control unit, without turning it, onto the actuator until no gap is visible on the form seal. NOTE! Too high torque when screwing in the fastening screw does not ensure protection class IP65 / IP67! The fastening screws may be tightened to a maximum torque of 1.5 Nm only. Attach the control unit to the actuator using the two side fastening screws. In doing so, tighten the screws only hand-tight (max. torque: 1.5 Nm). Fastening screws max. 1.5 Nm Supports Pilot air ports actuator Fig. 21: Install control unit Fig. 20: Aligning the puck holder Puck holder 26
Installation 8.3.4 Rotating the actuator The position of the connections can be aligned steplessly by rotating the actuator through 360. NOTE! Only the entire actuator can be rotated. The control unit cannot be rotated contrary to the actuator. Damage to the seat seal or the seat contour! When rotating the actuator, ensure that the valve is in open position. Procedure: Clamp the valve body in a holding device (applies only to valves which have not yet been installed). Control function A: Without unit control: pressurize the pilot air port 1 with compressed air (5 bar): valve opens. With unit control: open the valve according to the operating instructions for the control unit. Counter on the flats of the nipple with a suitable open-end wrench. WARNING! Risk of injury from discharge of medium and pressure! If the direction of rotation is wrong, the body interface may become detached. Rotate the actuator module in the specified direction only (see Fig. 22 )! Actuator with hexagon: Place suitable open-end wrench on the hexagon of the actuator. Rotate counter-clockwise (as seen from below) to bring the actuator into the required position. Actuator without hexagon: Fit special wrench 9) exactly into the wrench contour on the underside of the actuator. Rotate clockwise (as seen from below) to bring the actuator into the required position. Open-end wrench Special wrench with hexagon 10) Fig. 22: Rotating with special key / open-end wrench without hexagon 11) 9) The special key (identification number 00 665 702) is available from your Bürkert sales office. 10) Series production status since middle of 2011 11) Series production status up to middle of 2011. 27
Installation 8.4 Pneumatic connection DANGER! Danger high pressure in the equipment! Before loosening the lines and valves, turn off the pressure and vent the lines. WARNING! Risk of injury from unsuitable connection hoses! Hoses which cannot withstand the pressure and temperature range may result in hazardous situations. Use only hoses which are authorized for the indicated pressure and temperature range. Observe the data sheet specifications from the hose manufacturers. For control function I Danger if pilot pressure fails! For control function I control and resetting occur pneumatically. If the pressure fails, no defined position is reached. To ensure a controlled restart, first pressurize the device with pilot pressure, then switch on the medium. The pneumatic connection of the angle-seat control valve can be carried out only in connection with the appropriate control unit. Possible control units are: Positioner Type 8692, 8694 and 8696 Process controller Type 8693 8.4.1 Connection of the control medium Connect the control medium to the pilot air port (1) (3 7 bar; instrument air, free of oil, water and dust). Fit the exhaust line or a silencer to the exhaust air port (3) and, if available, to the exhaust air port (3.1). If used in an aggressive environment, we recommend conveying all free pneumatic connections into a neutral atmosphere with the aid of a pneumatic hose. Exhaust air port Pilot air port Additional exhaust air port only with pilot-operated control system for high air output (actuator size ø 130) Fig. 23: Pneumatic connection Control air hose: 3 1 3.1 6/4 mm or 1/4" pilot air hoses can be used. A pilot air port via G 1/8 thread is available as an option. 28
Electrical control unit 8.5 Start-up After installing the device, run the X.TUNE function. This function presets the control parameters. Description see operating instructions for the control. 8.6 Removal DANGER! Risk of injury from discharge of medium and pressure! It is dangerous to remove a device which is under pressure due to the sudden release of pressure or discharge of medium. Before removing a device, switch off the pressure and vent the lines. 9 ELECTRICAL CONTROL UNIT The valve Type 2300 can be combined with following control units: Type 8692 Type 8694 Type 8696 Type 8693 Positioner Positioner Positioner Process controller The electrical connection of the pilot valve or the control unit is described in the respective operating instructions for the pilot valve/control unit in the chapter titled Installation. Procedure: Loosen the pneumatic connection. Remove the device. 29
Maintenance, cleaning 10 MAINTENANCE, CLEANING 10.1 Safety instructions DANGER! Danger high pressure in the equipment! Before loosening the lines and valves, turn off the pressure and vent the lines. Risk of injury due to electrical shock! Before reaching into the system, switch off the power supply and secure to prevent reactivation! Observe applicable accident prevention and safety regulations for electrical equipment! WARNING! Risk of injury from improper maintenance! Maintenance may be performed by authorised technicians only! To screw on or unscrew valve body or actuator, use an openend wrench, never a pipe wrench, and observe tightening torques. Risk of injury from unintentional activation of the system and an uncontrolled restart! Secure system from unintentional activation. Following maintenance, ensure a controlled restart. WARNING! For control function I Danger if pilot pressure fails! For control function I control and resetting occur pneumatically. If the pressure fails, no defined position is reached. To ensure a controlled restart, first pressurize the device with pilot pressure, then switch on the medium. Risk of injury from moving parts in the device! Do not reach into openings. 10.2 Maintenance work Actuator: The actuator of the angle-seat control valve is maintenance-free provided it is used according to these operating instructions. Wearing parts of the angle-seat control valve: Parts which are subject to natural wear: Valve seat Control cone Seals If leaks occur, replace the particular wearing part with an appropriate spare part. (For spare-part sets see chapter entitled 12 Replacement parts ). 30
Maintenance, cleaning The replacing of the wearing parts is described in chapter 10.3 Replacing the wearing parts. Visual inspection: Perform regular visual inspections according to the application conditions: Check media connections for leaks. Check release bore on the tube for leaks. 10.3 Replacing the wearing parts 10.3.1 Replacing the control cone set The control cone set consists of Control cone Graphite seal Dowel pin Lubricant Before the control cone set can be replaced, the actuator must be removed from the valve body. Fig. 24: Release bore 10.2.1 Cleaning Release bore Commercially available cleaning agents can be used to clean the outside. NOTE! Avoid causing damage with cleaning agents. Before cleaning, check that the cleaning agents are compatible with the body materials and seals. DANGER! Risk of injury from discharge of medium and pressure! It is dangerous to remove a device which is under pressure due to the sudden release of pressure or discharge of medium. Before removing a device, switch off the pressure and vent the lines. WARNING! Risk of injury if the wrong tools are used! It is dangerous to use unsuitable tools for installation work as the device may be damaged. To remove the actuator from the valve body, use an openend wrench, never a pipe wrench. 31
Maintenance, cleaning Removing the actuator from the valve body Clamp the valve body in a holding device (applies only to valves which have not yet been installed). NOTE! Damage to the seat seal or the seat contour! When removing the actuator, ensure that the valve is in open position. Control function A: Without unit control: pressurize the pilot air port 1 with compressed air (5 bar): valve opens. With unit control: open the valve according to the operating instructions for the control unit. Using a suitable open-end wrench, place the wrench flat on the pipe. Unscrew the actuator from the valve body. Fig. 25: Valve Exhaust air port 2 Pilot air port Flats for openend wrench Valve body 1 Actuator Nipple Replace the control cone set Seal Spindle Dowel pin Control cone Fig. 26: Replacing the control cone set NOTE! Important information for the problem-free and safe functioning of the device! The sealing face of the control cone must not be damaged. Procedure: Knock out dowel pin with a suitable pin punch. Pin punch ø 4 mm, for spindle diameter 10 mm Pin punch ø 5 mm, for spindle diameter 14 mm Remove control cone. Attach new control cone to the spindle. Align bores of the control cone and spindle. 32
Maintenance, cleaning Support control cone on the cylindrical part with the aid of a prism or something similar. Put on dowel pin and carefully knock in with a hammer. Position the dowel pin in the centre of the spindle axis. Install the actuator (with control unit) on the valve body Check the seal and if required, replace it. WARNING! Danger if incorrect lubricants used! Unsuitable lubricant may contaminate the medium. In oxygen applications there is a risk of an explosion! In specific applications, e.g. oxygen or analysis applications, use appropriately authorised lubricants only. Grease nipple thread before re-installing the actuator (e.g. with Klüber paste UH1 96-402 from Klüber). NOTE! Damage to the seat seal or the seat contour! When installing the actuator, ensure that the valve is in open position. Control function A: Without unit control: pressurize the pilot air port 1 with compressed air (5 bar): valve opens. With unit control: open the valve according to the operating instructions for the control unit. Screw actuator into the valve body. Observe tightening torque (see Tab. 17 ). Fig. 27: Connections Pilot air port Tightening torques of valve body / nipples DN Tightening torques [Nm] 15 45 ±3 20 50 ±3 25 60 ±3 32 40 65 ±3 50 70 ±3 65 100 ±3 Tab. 17: Tightening torques of valve body / nipples 2 1 If the position of the pilot air ports for installation of the hoses is unfavorable, these can be aligned steplessly by rotating the actuator through 360. The procedure is described in the chapter entitled 8.3.4 Rotating the actuator. 33
Maintenance, cleaning 10.3.2 Replacing the packing gland The seal set for the packing gland contains SP10 / SP14 1 support ring 5 chevron seals 2 or 3 pressure rings 12) 1 pressure spring 1 seal Lubricant SP22 1 support ring 7 chevron seals 2 pressure rings 1 pressure spring 1 spacer 1 seal Lubricant SP10 SP14 DANGER! Risk of injury from discharge of medium and pressure! It is dangerous to remove a device which is under pressure due to the sudden release of pressure or discharge of medium. Before removing a device, switch off the pressure and vent the lines. WARNING! Risk of injury if the wrong tools are used! It is dangerous to use unsuitable tools for installation work as the device may be damaged. To remove the actuator from the valve body, use an openend wrench, never a pipe wrench. To replace the packing gland, use a special installation wrench, modified socket wrench or a socket wrench. Observe tightening torques. Before the packing gland can be replaced, the actuator must be removed from the valve body and the control cone removed. Tab. 18: Seal set for packing gland 12) depending on the spindle diameter (10 or 14 mm) 34
Maintenance, cleaning Removing the actuator from the valve body Clamp the valve body in a holding device (applies only to valves which have not yet been installed). Removing the control cone set Seal NOTE! Damage to the seat seal or the seat contour! When removing the actuator, ensure that the valve is in open position. Control function A: Without unit control: pressurize the pilot air port 1 with compressed air (5 bar): valve opens. With unit control: open the valve according to the operating instructions for the control unit. Pilot air port 2 Pilot air port Flats for openend wrench Valve body 1 Actuator Nipple Spindle Dowel pin Control cone Fig. 29: Replacing the control cone set NOTE! Important information for the problem-free and safe functioning of the device! The sealing face of the control cone must not be damaged. Procedure: Knock out the dowel pin with a suitable pin punch. Pin punch ø 4 mm, for spindle diameter 10 mm. Pin punch ø 5 mm, for spindle diameter 14 mm. Remove control cone. Fig. 28: Valve Using a suitable open-end wrench, place the wrench flat on the pipe. Unscrew the actuator from the valve body. 35
Maintenance, cleaning Replacing packing gland PEEK spindle guide (series production status up to April 2012): Unscrew the spindle guide with the aid of the installation wrench 13) and an open-end wrench. VA spindle guide (Series production status since April 2012): Unscrew spindle guide using a modified socket wrench 13). SP22: Unscrew the VA spindle guide with the aid of an open-end wrench. Packing gland tube Packing gland PEEK spindle guide Packing gland tube Packing gland VA spindle guide Spindle Hexagon Series production status since April 2012 Fig. 31: Replacing packing gland (VA spindle guide) Packing gland tube Series production status up to April 2012 Spindle Installation tool Packing gland Spacer Spindle Fig. 30: Replacing packing gland (PEEK spindle guide) VA spindle guide 13) The installation wrench or modified socket wrench is available from your Bürkert sales office. SP22 Fig. 32: Replacing packing gland SP22 36
Maintenance, cleaning WARNING! Risk of injury from parts jumping out! When the spindle opening is exposed, the individual parts of the packing gland are pressed out at an undefined speed when the pilot air ports is pressurized. Before pressurizing with control air, safeguard the ambient area of the discharge opening (e.g. place spindle on a firm base). If the valve features a PEEK spindle guide (series production status up to April 2012), we recommend replacing it with a VA spindle guide (see Tab. 25: VA spindle guide for packing gland, page 42) Grease thread of the spindle guide (Klüber paste UH1 96-402). Screw spindle guide back in using the installation tool. Observe torque (see Tab. 19: Tightening torques of spindle )! Pilot air port 2 Fig. 33: Connections Pilot air port 1 Press out packing gland: Control function A and I Pressurize pilot air port 1 with 6 8 bar. Control function B Pressurize pilot air port 2 with 6 8 bar. Grease the individual parts of the new packing gland with the upplied lubricant. Connect the individual parts to the spindle in the specified direction and sequence (as illustrated in Fig. 34 or Fig. 35 ). Push packing gland into the packing gland tube. Insertion direction for packing gland parts Support ring Upper chevron seals Upper pressure ring(s) Pressure spring Lower pressure ring Lower chevron seals Spindle diameter 10 mm Spindle diameter 14 mm Fig. 34: Seal set for packing gland SP10 / SP14 37
Maintenance, cleaning Insertion direction for packing gland parts Support ring Upper chevron seals Upper pressure ring(s) Pressure spring Lower pressure ring Lower chevron seals Spacer Tightening torques of spindle Spindle diameter Orifice body Material of spindle guide Tightening torque [Nm] 10 mm PEEK 6 15 1.4401 / 1.4404 15 20 25 / 316L 25 32 50 14 mm PEEK 15 25 1.4401 / 1.4404 25 32 50 / 316L 60 22 mm 65 1.4401 / 1.4404 60 Tab. 19: Tightening torques of spindle Spindle diameter 22 mm Fig. 35: Seal set for packing gland SP22 Installing the control cone Attach new control cone to the spindle. Align bores of the control cone and spindle. Support control cone on the cylindrical part with the aid of a prism or something similar. Put on dowel pin and carefully knock in with a hammer. Position the dowel pin in the centre of the spindle axis. 38
Maintenance, cleaning Install the actuator (with control unit) on the valve body Check the seal and if required, replace it. WARNING! Danger if incorrect lubricants used! Unsuitable lubricant may contaminate the medium. In oxygen applications there is a risk of an explosion! In specific applications, e.g. oxygen or analysis applications, use appropriately authorised lubricants only. Grease nipple thread before re-installing the actuator (e.g. with Klüber paste UH1 96-402 from Klüber). NOTE! Damage to the seat seal or the seat contour! When installing the actuator, ensure that the valve is in open position. Control function A: Without unit control: pressurize the pilot air port 1 with compressed air (5 bar): valve opens. With unit control: open the valve according to the operating instructions for the control unit. Screw actuator into the valve body. Observe tightening torque (see Tab. 20 ). Fig. 36: Connections Pilot air port Tightening torques of valve body / nipples DN Tightening torques [Nm] 15 45 ±3 20 50 ±3 25 60 ±3 32 40 65 ±3 50 70 ±3 65 100 ±3 Tab. 20: Tightening torques of valve body / nipples 2 1 If the position of the pilot air ports for installation of the hoses is unfavorable, these can be aligned steplessly by rotating the actuator through 360. The procedure is described in the chapter entitled 8.3.4 Rotating the actuator. 39
Malfunctions 11 MALFUNCTIONS Malfunction Actuator does not switch. Remedial action Pilot air port interchanged 14) CFA: Connecting pilot air port 1 CFB: Connecting pilot air port 1 CFI Tab. 21: Malfunctions - 1 Pilot air port 1: Open Pilot air port 2: Close Pilot pressure too low See pressure specifications on the type label. Medium pressure too high See pressure specifications on the type label. Flow direction reversed See direction arrow on the type label. Malfunction Valve is not sealed. Valve is leaking on the release bore. Tab. 22: Malfunctions - 2 Remedial action Dirt between seal and valve seat Installing dirt trap Seat seal worn Installing a new control cone Flow direction reversed See direction arrow on the body. Medium pressure too high See pressure specifications on the type label. Pilot pressure too low See pressure specifications on the type label. Packing gland worn Replacing packing gland. 14) See Fig. 23: Pneumatic connection. 40
Replacement parts 12 REPLACEMENT PARTS WARNING! Risk of injury when opening the actuator! The actuator contains a tensioned spring. If the actuator is opened, there is a risk of injury from the spring jumping out! The actuator must not be opened. CAUTION! Risk of injury and/or damage by the use of incorrect parts! Incorrect accessories and unsuitable replacement parts may cause injuries and damage the device and the surrounding area. Use only original accessories and original replacement parts from Bürkert. 12.1 Replacement part sets Replacement part sets for the angle-seat control valve Type 2300: Control cone set consisting of control cone, dowel pin, seal and lubricant. Sealing set for packing gland consisting of the individual parts of the packing gland, seal and lubricant (the (modified) socket wrench is not included in the sealing set). Spindle guide for packing gland consisting of VA spindle guide, seal and lubricant. Control cone set DN Actuator size Order no. [mm] PTFE / Steel Steel / Steel 15 50, 70 170 315 170 322 20 50, 70 170 316 170 323 25 50, 70, 90 170 318 170 324 32 70 170 319 170 325 90, 130 226 941 226 925 40 90, 130 226 945 225 423 50 90, 130 226 948 225 426 65 130 226 950 225 427 Tab. 23: Control cone set Sealing set for packing gland Spindle [mm] DN 10 15 32 14 25 50 Actuator size [mm] 50 70 90 130 Order no. 216 436 216 438 22 65 130 252 545 Tab. 24: Sealing set for packing gland 41
Replacement parts VA spindle guide for packing gland Spindle DN Actuator size Order no. 15 50, 70 246 577 10 20 / 25 50, 70 246 578 32 70 246 582 25 90 246 579 14 32 90, 130 246 583 40 90, 130 246 593 50 90, 130 246 594 22 65 130 252 544 Tab. 25: VA spindle guide for packing gland 1 Seal 2 Control cone Control cone set 3 Dowel pin 4 Sealing set for packing gland SP10 / SP14 5 Sealing set for packing gland SP22 6 VA spindle guide SP10 / SP14 7 VA spindle guide SP22 1 4 5 2 3 6 7 Fig. 37: Replacement parts 42
Packaging, transport, storage 12.2 Installation tools Only for PEEK spindle guide: Installation wrench for packing gland (Series-production status until April 2012) Installation wrench Order no. Spindle diameter 10 mm 665 700 Spindle diameter 14 mm 665 701 Tab. 26: Installation wrench for PEEK spindle guide Modified socket wrench for packing gland (Series production status since April 2012) AF Socket wrench Orifice DN AF Order no. Spindle 10 mm 15 19 683 220 Spindle 10 mm 20 32 21 683 222 Spindle 14 mm 25 50 21 683 223 Tab. 27: Modified socket wrench Only for actuator without hexagon: Special wrench for rotating the actuator (Series-production status until end of 2011) Order no. 665 702 Tab. 28: Special wrench for actuator without hexagon If you have any queries, please contact your Bürkert sales office. 13 PACKAGING, TRANSPORT, STORAGE NOTE! Transport damages! Inadequately protected equipment may be damaged during transport. During transportation protect the device against wet and dirt in shock-resistant packaging. Avoid exceeding or dropping below the permitted storage temperature. Incorrect storage may damage the device. Store the device in a dry and dust-free location! Storage temperature -20...+65 C. Damage to the environment caused by device components contaminated with media. Dispose of the device and packaging in an environmentally friendly manner. Observe applicable regulations on disposal and the environment. Note: Observe national waste disposal regulations. 43